2429109 - 2110A10 manual gearbox and differential - r + r

Removing ( Refitting ) Position the vehicle on the ramp. Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with removal  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with removal  - 7055B90  Left front WHEEL ARCH LINER - R.R. . Proceed with removal  - 5530B10  battery - r+r . Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with removal  - 1048A10  air cleaner filtering element - replace . 1. Undo the bolts (1a) and move the clutch operating cylinder (1b) aside without disconnecting the pipe.2. Undo the nut (2a) and disconnect the battery earth lead (2b) from the gearbox.

NameConnector
2bBattery earth  C1 
3. Disconnect the electrical connection from the reversing lights switch.

NameConnector
3Reversing lights switch  I20 
1. Undo the bolts (1a) fixing the gear selector and engagement cables mounting bracket (1b).2. Press the release button (2a) and disconnect the gear selector cable (2b). 3. Disconnect the gear engagement cable.Move the gear selector and engagement cables, complete with mounting bracket, sideways.
1. Undo the plug and drain the manual gearbox and differential.
Collect the manual gearbox and differential oil in a suitable container.
1. Undo the nuts (1a) and disconnect the track rods (1b) from the steering knuckles usiing the tool (1c).

NameCountry
1cExtractor1.871.000.700
2. Undo the bolts fixing the front hub steering knuckle to the front shock absorbers.
1. Loosen the bands (1a) and disconnect the driveshafts (1b ).
Position a hydraulic jack under the gearbox.1. Undo the bolt (1a) and the bolt (1b) and remove the power unit lower reaction rod (1c).Remove the hydraulic jack from under the gearbox.
1. Undo the top bolts securing the manual gearbox with differential to the crankcase.2. Undo the front bolt fixing the starter motor.
1. Open the cover (1a), undo the nuts (1b) and disconnect the electrical connections (1c) for the alternator.

NameConnector
1cStarter' motor  A20 
2. Undo the rear bolt (2a) and remove the starter motor (2b).
1. Undo the bolt fixing the lower radiator crossmember to the bodyshell.2. Fit the tool (2a) and secure it using the bolts (2b).
The above bolts are fitted in place of the bolt fixing the lower radiator crossmember to the bodyshell and in place of the bolt fixing the power unit lower reaction rod to the front suspension crossmember.

NameCountry
2aCrossmember1.870.595.000
1. Undo the bolts fixing the power unit gearbox side rigid support to the flexible mounting.
1. Release the supply pipe from the master cylinder (1a) from the bands (1b) on the flexible mounting for the gearbox side rigid power unit support.2. Undo the bolt (2a) and remove the power unit gearbox side rigid engine mount (2b).
1. Loosen the bolt fixing the manual gearbox and differential to the crankcase.2. Undo the bolt fixing the engine flywheel protective cover to the manual gearbox and differential.3. Undo the bolt (3a) and the bolt (3b) fixing the manual gearbox/engine bracket, gearbox side.4. Undo the bolt fixing the exhaust manifold and catalytic converter mounting bracket to the gearbox.5. Undo the bolt fixing the manual gearbox and differential to the cylinder block/crankcase.
1. Fit the tool (1a) and hydraulic jack (1b) on the manual gearbox and differential.

NameCountry
1aGearbox mount1.860.873.000
2. Completely undo the bolt loosened previously fixing the manual gearbox and differential to the crankcase.3. Remove the manual gearbox with differential, first moving it away from the engine and then lowering it slowly with the hydraulic jack.
Take care not to damage the engine compartment components whilst removing the manual gearbox and differential.
Refitting ( Removing ) Place the manual gearbox and differential back in its housing using the hydrauilc jack and support tool.Temporarily secure the manual gearbox and differential to the crankcase using the bolt.Remove the manual gearbox and differential support tool and the hydraulic jack.

NameCountry
-Gearbox mount1.860.873.000
1. Tighten the bolt fixing the manual gearbox and differential to the crankcase to the recommended torque.

FasteningComponentØValue(daNm)
1BoltMANUAL GEARBOXM12(Crankcase side) 7.2 ÷ 8.8
2. Tighten the bolts fixing the manual gearbox and differential to the crankcase to the recommended torque.

FasteningComponentØValue(daNm)
2BoltMANUAL GEARBOXM12(Crankcase side) 7.2 ÷ 8.8
3. Tighten the bolt (3a) and the bolt (3b) fixing the manual gearbox/engine mounting bracket, gearbox side, to the recommended torque.

FasteningComponentØValue(daNm)
3aBoltGEARBOX/ENGINE COUPLING BRACKETM12(Gearbox side) 5.0 ÷ 6.1

FasteningComponentØValue(daNm)
3bBoltGEARBOX/ENGINE COUPLING BRACKETM12(Gearbox side) 5.0 ÷ 6.1
4. Tighten the bolt fixing the exhaust manifold and catalytic converter mounting bracket to the gearbox to the recommended torque.

FasteningComponentØValue(daNm)
4BoltMANUAL GEARBOXM10(Bracket side) 4.5 ÷ 5.5
5. Tighten the bolts fixing the engine flywheel protective cover to the manual gearbox and differential.
1. Refit the gearbox side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltPOWER UNIT GEAR BOX END RIGID MOUNTM10(Gearbox side) 4.5 ÷ 5.5
2. Fasten the supply pipe from the master cylinder (2a) using the bands (2b) on the flexible mounting for the gearbox side rigid power unit support.
1. Undo the bolt fixing the gearbox side rigid power unit support to the flexbile block to the specified torque.

FasteningComponentØValue(daNm)
1BoltPOWER UNIT GEAR BOX END RIGID MOUNTM12(Flexible mounting side) 8.1 ÷ 9.9
Remove the safety tool used for supporting the power unit.

NameCountry
-Crossmember1.870.595.000
Tighten the bolt securing the radiator bottom crossmember to the bodywork.1. Place the starter motor (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltSTARTER MOTORM82.4 ÷ 3.0
2. Connect the electrical connections (3a) to the starter motor, fix them using the nut (2b) and close protective cover (2c).
1. Refit the lower power unit reaction rod (1a) back in its seating, then secure it with the bolt (1b) and bolt (1c) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltLOWER ROD ON ENGINEM12(Gearbox side) 7.2 ÷ 8.8

FasteningComponentØValue(daNm)
1cBoltLOWER ROD ON ENGINEM12(Front suspension crossmember side) 11.4 ÷ 12.6
Connect the driveshafts and tighten the bands.1. Tighten the front wheel hub fastening bolts to the front shock absorbers to the recommended torque.

FasteningComponentØValue(daNm)
1BoltFRONT HUB STEERING KNUCKLE.M10(Shock absorber side) 6.2 ÷ 6.8
2. Connect the steering rods (2a) to the front steering knuckles and tighten the nut (2b) to the recommended torque.

FasteningComponentØValue(daNm)
2bNutADJUSTABLE STEERING LINKSM10(Steering knuckle side) 3.6 ÷ 4.4
1. Tighten the manual gearbox and differential fluid drain plug to the recommended torque.

FasteningComponentØValue(daNm)
1Drain plugGEAR CASING PADSM16(Differential side) 1.6 ÷ 2.0
Place the gear selector and engagement cables, complete with mounting bracket, back in their housings.Connect the gear selector cable.Connect the gear engagement cable.Tighten the bolts fixing the gear selector and engagement mounting bracket.Connect the electrical connection to the reversing lights switch.Connect the earth lead and tighten the nut.Replace the clutch operating cylinder, then fix it tightening the bolts to the recommended torque.

FasteningComponentØValue(daNm)
-BoltCLUTCH SLAVE CYLINDERM8(Gearbox side) 1.6 ÷ 2.4
Proceed with refitting  - 1048A10  air cleaner filtering element - replace . Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Proceed with refitting  - 7055B90  Left front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r . Refill the manual gearbox and differential  - 0010T41  MANUAL GEARBOX OIL - Check level and top up, if necessary . Remove the car from the ramps.